Rug



Nov. 12, 1935. Y J. H. PATRICK 2,020,699

RUG

Filed oct. 2e, 1955 2 sheets-sheet 1 Wam.

ATTORNEY Nov. 12, 1935. J. H, PATRICK 2,920,699

RUG

Filed OCL. 26, 1935 2 Shee'bS-Sheel 2 INVENTOR M ATi'oRNEY Patented Nov. 12, 19935 UNITED STATES PATENT CFFICE 1 Claim.

'Ihis invention relates to rug making, and, more particularly, aims to provide an improved type of rug, and an improved method of fabricating a rug, where such rug presents a rectangular Vfield and a surrounding border. x

The invention has been made with the idea of providing a rectangular rug, of a given decorative design including at least a distinctive border` portion along each of its four sides to mark ofi a central rectangular field, and fabricated by up holstering together a plurality of separately woven elements, yet a rug so made that, according as said elements are dilferently relatively proportioned before being upholstered together, the rug when completed will have a greater or less length or width, or, when desired, both a greater cr less length and a greater or less width, in agreement with special order comprising predetermined size or dimensional requirements, but will always present the rectangular eld, the surrounding border and such other pattern features as are characteristic of said given design, will always have the pile of the rug lie` substantially uniformly all over the same when completed just as if woven in one piece but will be composed solely of a plurality of rectangular separately woven elements, and will have a line of upholstering nowhere crossing said field.

The present invention provides such a rug, and one satisfying various special objects of the invention, as will now be mentioned. Since all the weven elements which are combined by uphol.

stering are rectangular, there is no wastage of material due to mitering; and because there is no mitering, a fiat-lying and wrinkle-free rug can always easily be produced, of any size ordered within the limits predetermined, by even such carpet-upholstering personnel and sewing machines as a jobber or large retailer commonly maintains. There are no diagonal lines of upholstering anywhere in the rug; but, instead; all lines of upholstering are unidirectional and coincident with bounding edges of the central field of the rug-there in fact being, as will be understood in a moment, very few of these lines. In order to have all the lines of upholstering thus coincident with bounding edges of said field, the rug includes in its make-up no woven element containing merely a part of said iield. On the other hand, the new rug includes in its makeup no woven element which presents, in addition to the field, a border portion and also a perpendicularly converging border portion; and so the woven element which includes the complete field of the new rug can be merely a cut-off length of a wide or broadloom carpet roll woven to include said iield. At the same time, no cornerpattern element, whether in the form of a medallion or other configuration, a line-joining or a plurality of line-jonings, a 'spacing between gures or lines, or otherwise, and which, however constituted, is always a particularly prominent and conspicuous feature of any bordered rug, is bisected in the completed rug of the present invention by aline of upholstering itself likely to beV 5 observed readily because runningfrom a corner of the eld to a corner of the rug.

One of the important features of the present invention is not only the separate weaving of a plurality of elements all of which are rectangular and combined to make an upholstered rug as hereinabove explained, but the weaving of these elements in such manner, as all on the same loom, and with the same tension setting when the different elements are woven, that when said elements are spaced and faced relative to each other, to arrange their meeting edges to establish the desired design matchings in the rug to be completed by upholstering them together, the piles of all of said elements will extend in substantially 20 the same direction, so that in the completed rug the pile thereof will lie substantially uniformly all over the same; thereby to aid the one thing needed to make the new rug practically indistinguishable, under ordinary observation, from a 25 unitarily woven rug of a standard or special size.

The completed rug pursuant to the invention will always consist of at least three rectangular rug portions secured together, this securement being as aforesaid along merely two unidirectional 30 and parallel lines of upholstering neither of which crosses any part of the field of the rug. According to one way of carrying out the invention, each of these three or more rug portions can be a unitarily woven rectangular element; and according to another way of carrying out the invention, each of these three or more rug portions, or one or more of them, can be in the form of two rectangular woven elements secured together by a line of upholstering which does not 40 cross any part of the eld, which does not diagonally cross any part of the rug, and which does not traverse any corner-pattern element of the rug. Always, however, there are incorporated in the rug three or more rug portions having the characteristics next described. First, there is always provided, as the main component of the rug, a rectangular woven element in the form of a single cut-orf length of, or other single section cut from, a broadloom lcarpet roll woven to in- 50 clude the central rug field in its entirety and a border portion at one or both of the bounding edges of said field which extend lengthwisely of the roll. Also, there are always provided, as two edge components for the rug, eachV to close in said field along a bounding line thereof which is perpendicular to a bordered edge of said main component, a pair of elongate rectangular woven elements which presents border-pattern elements only, but which, in presenting these, present not only the required border portions to lie along two opposite bounding edges of said field but also, at each of the opposite ends of the borderV various now preferred embodiments of the in-V vention as illustratively shown in the accompanying drawings.

Fig. 1 shows a step in the making of a rug to have a special width and a standard length, or a special length and a standard width, and so most conveniently having each of the aforesaid rnain and edge-component rug portions woven unitarily-this View showing Vsuch three portions separately, and spaced one from another, but arranged so that the various edges thereof which are to be joined by lines of upholstering to combine said portions into the completed rug face and align with each other as they will face and align in the completed rug;

Fig. 2 shows said rug completed;

Fig. 3 is an enlarged fragmentary view, showing two of the rectangular woven portions of a rug structurally similar to that shown in Fig. i,

but with these rug portions rather elaborately patterned as compared with the very simple patterning of the corresponding rug portions of Figs. 1 and 2; Y

Figs. 4, 5, 6 and 7, respectively, illustrate various woven elements as employed in the making of a rectangular rug having both of its two dimensions speciaL-Fig. 4 showing a stretch of a broadloom woven carpet roll which isbordered only at one side thereof, Fig. 5 showing an auxiliary or complementary carpet roll which presents merely a border matching the border last referred to, Fig. 6 showing one of the two edge components aforesaid, and Fig. 7 showing the other thereof;

Fig. 8 shows the completed rug, as made up from the woven elements shown in Figs. 4, 5, 6 and 7; Y

Y Fig. 9 illustrates a stretch of a broadloom woven carpet roll which is like that of Fig. 4 except that it is bordered at both sides` thereof, and, in broken lines, possible cuttings which can be made to utilize this roll in a way to avoid any need to provide the roll of Fig. 5 even when a rug special both as to width and length is to be made;

Fig. 10 shows a stretch ofV a broadloom carpet roll woven to repeat therealong edge-component rug portions corresponding to those shown'in Fig. 6;

Fig. 11 shows a stretch of a broadloom carpet roll woven to repeat therealong edge-component rug portions corresponding to those shown inrFig. 7; and

Fig. 12 shows a stretch of a broadloom carpet roll woven to repeat alternately therealong edgecomponent rug portions corresponding to those shown in Figs. 6 and 7. y

Similar reference characters refer to similar parts throughout the several views of the drawings. Y

Referring now to these drawings in detail, and more particularly to Figs. 1 and Consumer demand for rugs of other than standard sizes has been found to be chiefly for a rug of Vagreater or less width `or length only, that is,

of a broadloom carpet roll I6 woven to present said field at F and border portions A and B extending lengthwisely .of the roll along the opposite side edges thereof. And the completed rug will consist merely of a unitarily woven main rug portion l5, and two edge components for.

the rug, these last being elongate rectangular auxiliary elements I1 and I8 each unitarily woven and bothpresenting certain pattern elements, with, however, each element i7 or I3 a reversal of the other so far as the pattern elements presented thereby are concerned. The pattern elements presented by each of the woven elements l'l and I3 include not only border portions C and D matching each other and the border portions A and B, but, also, at each of the opposite ends of the border portions C and D, the configuration or configurations or the spacing or spacings between configurations, here shown as the pattern elements G including both configurations and spacings therebetween, which in the completed rug will be the `pattern elements at the four corners thereof, that is, common to the meetingrends of any perpendicularly converging pair of border portions A, B, C and D. Said corner pattern elements G, therefore, since there is no mitering of different portions of the rug required to establish the same, will of course never be distorted along a diagonal line, and will be protected against lack of uniformity of appearance and wear all over; and, further, will always be unmarked'by any line of upholstering anywhere crossing the same.

In order to complete the rug, it is merely necessary to secure together the woven elements l5,

Vi and i8 of Fig. 1, as by any suitable type of sewing-machine of a kind well-known in the art of upholstering carpet, along two straight and parallel lines of upholstering. In Fig. 2, one of. these lines is partially indicated at I9, i 9 and the other at 2e, 2B; the first-mentioned line resulting from the joining together of the edges of elements i5 and I1 marked l5 and I'I' in Fig. l, and the other from the joining together ofthe edges of elements l5 and I8 marked lEPand I8 in Fig. l. Eachof said lines is a unidirectional one as long as either of the woven elements lll and -l 8; neither of said linescrosses the field anywhere but merely marks off a complete bounding edge of said field, and both of said lines, beyond the limits of the field, inconspicuously continue totwo opposite edges of the rug by crossing the border surrounding the field at points where it is very common in even elaborately patterned unitarily woven rugs to have aV border portion irregularly terminate (as by,V omission of a part of a borderdesign repeat unit, or a shortening or other distortion of Vsuch unit, or even by the interpolation of a pattern element different from such unit) to mark off the beginning of the corner-pattern area.

n such a very simple border design as that shown in Figs'. 1 and 2,'there will of course be absolute matching of design elements all around the border surrounding the field F.

.The present invention, howevenis readily applicable to the making up of a rug having an elaborately figured border, and/or an elaborately patterned eld; and, indeed, to any rug design except perhaps those comparatively infrequent ones where the pattern-repeat units for either eld or border are unusually large or unusually plain or unusually widely spaced.

Referring to Fig. 3, this serves somewhat to illustrate the availability of the present invention over a practically limitless range of different rug designs highly elaborate as to held-design repeatunits and as to border-design repeat units; even where the completed rug, in order to satisfy an unusually critical purchaser who desires a rug of a special size, must closely simulate a unitarily woven one. The eld and border designs shown in Fig. 3 are typical of an immense class of unitarily woven rugs, including the Persians and other orientale and quasi-orientals and the great majority of the more favored occidental designs, wherein border portions are frequently terminally unique as just above pointed out, wherein the field is often made up of pattern elements of large area indiscriminately fractionally shown alongside the four bounding edges of the ield, and wherein all over the rug adjoining pattern elements are not marked off from each other by garishly contrasting colors or denitely and prominently located lines of abrupt inter-jolnder. Assume that a broadloom carpet roll like the roll iii of Fig. l is woven to present field and border designs like those indicated in Fig. 3; that 2l represents a cut-off length of such roll to provide a main rug portion corresponding to that shown at i5 in Fig. l, and that 22 represents an edge component for said main rug portion corresponding to that shown at I8 in Fig. l. If the rug to be made is to have a dimension longitudinally of the border portion BX of woven element 2l such that the line of upholstering which is to secure together the two woven elements 2l and 22 along the top edge of the latter will lie at, say, any one of the dot-and-dash lines 2 l shown on the element 2 i, the lower end of the border BX thus established will in any case merge, in a manner which is quite customary in unitarily woven rugs, with the left end of the border portion presented by the woven element 22. If the differently colored areas making up the border pattern are, as is usual, fairly soft and subdued one relative to another, the fact that the rug is not a unitarily woven one will be especially difficult to detect. The uniformity of lie of pile all over the completed rug will completely hide the directions of extension and even the presence of the lines of upholstering employed in building up the rug; so that an inspection of the back of the rug is necessary in order to determine absolutely that the same is not a unitarily woven one.

When the invention is carried out by the use of a broadlo-om carpet roll like that described in connection with Figs. l and 2, not only can a square rug be provided wherein each of the four bounding edges thereof is as long as the said roll is wide, but there can also be provided a rug of a standard width and a special length or a rug of a standard length and a special width, according as the cut-off length of the roll selected for the main Woven portion o1 the completed rug has its greater dimension lengthwisely of the roll or laterally thereof.

Pursuant to the present invention, further, a built-up rug having a uniformly extended pile all over and otherwise normally indistinguishable from a unitarily woven rug can be provided which is variable not only as to length or width as just explained, but also as to both Width and length. To take care of such double-dimensional variation, a preferred Way of carrying out the invention is as follows:

Referring to Figs. 4 to 8, a broadloom carpet roll 23 is so woven that it includes a rug eld F of any selected design which is wide enough across the roll to make the maximum rug Width predetermined to be made from that roll. Roll 23 includes a border A at one only of the two side edges of the roll. First, a length of this roll is cut off, as by making the cut H, to that extent required for the special length of, rug to be made; and then (assuming the width of the rug to be made is also special, in that it is to be less than the predetermined maximum aforesaid) said cutoff length of the roll is side-trimmed along its edge parallel to the bordered edge thereof, as by making the cut J, to remove the amount of material required to allow for the difference between said maximum and special widths.

The next step is to form a main rug portion by combining the main rug element or section Z provided as just-described, with another separately woven element, by a single unidirectional line of upholstering. The last-mentioned woven element is an elongate rectangular one to provide the required border portion B along said trimmed edge of the section 24, and is in the form of a cutoff length or section 25 of a separately woven carpet roll 2li, hereinafter called the border roll. Said border roll presents along the whole length of the same the same border pattern as is presented along the entire length of the roll 23, hereinafter called the main roll. Said cut-off length of the border roll is so cut therefrom, as by making the cut K, that it is exactly as long as said trimmed edge of the section 24 of the main roll. These two sections are then secured together by a single straight line of upholstering, to join them together at the said trimmed edge of the section 24 and at the edge 25 of the section 25, thereby to make a built-up main rug portion 24-25. In order that when the two Woven elements 24 and 25 are thus upholstered together the said main rug portion 24-'25 will have matching border portions A and B along the two sides thereof, the section 25, in being cut from the rolll 26 to the proper length, is also so cut therefrom, when the nature of the border pattern requires, that it will have the border pattern elements arranged therealong as they are on the section 24.

Finally, the unbordered edges of this main rug portion 24-25 are completed, and the rug is finished, exactly as has been explained in connection with the upholstering together of the rug of Figs. 1 and 2; that is, by the upholstering to each of said edges, of an elongate rectangular auxiliary woven edge component which presents not only a border portion matching those now in the rug portion 24-25, but also, at each end of said component, the pattern elements common to the border portion thereon and also to the border portions A' and B.

These two edge components are shown at 21 and 28.

As the invention is preferably carried out, the edge components 2l and 28 for any particular rug pattern are not woven to different lengths4 ing the border portion A. Then, where the rug to be made includes a section of the main roll 23, as the section 2t, trimmed away along the edge thereof opposite to the bordered edge, as along the cutting line I, each of said edge components 21 and 25, before being upholstered to the main portion 2li-25 of the rug to complete the latter, is cut away intermediate its ends and the two terminallengths thereof are secured together by a line of upholstering perpendicular to the length of said edge component; each such component being thus cut away, as by making the two lines of cut indicated at L on each of said components in Figs. 6 and 7, to the extent required properly to and 28 presents a border portion C or D pursuantr to the invention and including pattern elements G' at the ends of the component which will form corners of the rug. These elements G will always be properly present in the rug, regardless of how much the edge components are shortened Yby cuts like those at L before being reconstructed by the upholstering together ofV their terminal lengths as above described.

The two nal lines of upholstering in completing the rug by joining the edge components 2l' and 28 to the main rug portion lill- 35 are those indicated at B, 29 and St, it in Fig. 8, but both running completely across the rug, that is, in the case of the edge component 2, to join the edge 2l thereof to the edge of the inain rug portion 2fl-25 resulting from the cuttings I-I and K, and, in the case of the edge component to join the edge 28' thereof tothe edge of the main portion Eil-25 made up of the edge 24' of the element 24 and the edge 25 of the element 25.

ln making a rug special as to both length and width pursuant to the invention as above described, it is not necessary, however, to provide a separate border carrying roll, as the rollV 26 of Fig. 5.

Referring in this connection to Fig. 9, there can be provided, as shown at 3l, a wid-eloorn woven carpet roll like the roll l5 oi Fig. l. in that it is bordered along both the roll edges, as at A and tension along the length of the roll to permitV making the rug of the desired length, such a section of the roll 3l, for instance, as would be cut therefrom by making the two straight cuts F and Q all the way across theroll-so that said rug can be completed merely by the addition of two edge components as already explained. When, however, the rug to be made, in addition to having a special length, is to have a special width less than that of said predetermined maximum, the necessary material is removed from the field F, as that between the broken lines Pt and S, by cutting said section along said lines. Then, to

provide a built-up main rug portion as described pieces of said section left after discarding the cutaway material are upholstered together along the joined lines R and S--the piece including the eld F and the border portion A corresponding to the section 24 of Fig. 4, and the piece including the 5 border portion B corresponding to the section 25 of Fig. 6.

Referring nally to Figs. 10, l1 and l2, these illustrate how broadloom woven carpet rolls can be woven to provide, regularly therealong and 10 to be cut therefrom as required, the edge components 21 and 28 oi Figs. 6 and 7; instead of providing said edge components as individually woven elements delivered from the loom independently one after another, that is, one discon- 15 nected from another, as the edge components hereinabove .described have been assumed to be made. There are shown in Figs. lo, ll and l2 stretches of such rolls; the roll of Fig. l@ having edge components 2i repeated therealong, the roll 20 of Fig. ll having edge components 2% repeated therealong, and the roll of Fig. l2 having edge components 2l' and 2S repeated therealong in alternation. On each roll, between each two adjacent edge components, are auxiliary weavings, 25"

'so that when an edge component El or is cut from a roll, as indicated by the broken lines, not only will extra wovon similar to the extra woven material shown at T, T in Fig. l and at T in each of Figs. 5, 6 and 7, be available for the line of upholstering to secure one long edgeY of such edge component to the main rug portion to which it is to be applied, but extra material will also be available for nishiim' ofi the other edge of said edge component at an end of 35" i the completed rug, or at a side thereof, Yas the may be. i

As shown at U in l, the edge components for the rug can be fringed, either by stitching on such fringes, or by weaving such a fringe as a part of the edge component to carry the same.

All the various woven components for the new rug are, as already explained, woven in a way to have the pile of each so lie that in the .completed rug the pile thereof will extend substan- 4 tially inthe same direction all over the rug. In other words, all the various elements which are separately woven, are so woven that when they are relatively arranged as shown in the drawings, the piles of all thereof will extend, say, substantially in the direction indicated by the arrows V of Figs. l, 3, 4, 5, o', 7, l0, 1l and 12.

It will be seen that by the present invention built-up rugs of special and unusual sizes and proportions, yet presenting designs including fields and surroundhigY borders as in unitarilyV woven rugs, can be readily fabricated from separately woven elements, with such elements woven to particular sizes or otherwise, but with at least one of said elements always a portion of a broadloo'm carpet roll woven to include the field in its entirety and a border portion extending along at least one bounding edge of said iield; and, further, with said woven elements secured together by lines of upholstering inconspicuously located because failing to cross any part oi the field or a corner-pattern area of the rug and at the time indistinguishable due to the fact that, while a plurality or said woven elementsV are separately woven; they are all nevertheless soV woven that, Vregardless ofV how'said elements are rearranged Yto obtain matching or symmetry between design elements of different border portions, Ythe pile is substantially uniformly extended all over the completed rug.

The new rug need not be made up to any size whatever at the weavers factory or anywhere until an order for a particular size rug is received; and the mill customers, as its jobbers and retailers, can be supplied merely with the broadloom carpeting and the other woven elements appropriate to a particular rug pattern, for cutting and upholstering according to the invention as the orders of their own customers are received. The resulting rug can be sold at a lower price than is possible with a unitarily woven rug oi the same size and quality, even when the latter is of a standard size, in View of the economies permitted in connection with each of the multitude of rug patterns having to be carried on hand to meet modern competition. As to every one of such rug patterns, there is sometimes, and as to many of such rug patterns, there is always, a saving resulting from the fact that a large stock of rugs of each of the numerous common sizes need not be completed at the factory, or kept in stock by the dealer, in anticipation of possible orders therefor which do not materialize. Again, in the making of the woven elements employed by the invention, a saving results from the fact that, as to each rug pattern adopted, the present general practice of having a different loom set-up not only for each diierent rug pattern but ier each of the numerous common standard sizes of rug to carry that pattern, so that each of all these loom set-ups consists of a repeat equal in magnitude to the total length or width oi the entire rug, is completely done away with. While, in the case of each pattern adopted, several different loom set-ups may be necessary for several dilierent woven elements of the invention, each of these will be a relatively short repeat, even for the weaving of the wideloom -carpet roll including the rug iield where, as is recommended, the repeat of said l'ield, whether equal in length to the repeat of the border, or longer or shorter than the latter, is not out of step with the same.

Whenever a plurality oi woven elements are herein referred to as being separate woven ones, or separately woven, there is not necessarily meant, for instance, that each of said plurality of elements is woven at a different time or otherwise independently from another, but merely that said plurality oi elements, if directly interwoven with each other or woven as spaced parts of a unitarily woven element, are separate and distinct one from another in the sense that they are to have certain special locations in the completed rug. For example, there would fall Within the definition just given the edge components 2l and .2S as woven pursuant to Figs. 10, 11 and l2, when cut from their rolls; as would the element 2A of Fig. 4. and the element 25 oi Fig. 5, after being cut from their rolls, even though such rolls were simultaneously woven in the same loom; and as would the two hereinabove described cuttings from the roll 3| of Fig. 9, one between the lines P, Q and R and the other between the lines P, Q and S.

Herein, and in the appended claim particularly, whenever a woven element is characterized as providing a border, there is meant one of the straight stretches of the field-surrounding border of the completed rug which is coextensive with a bounding edge of said rug from end to end of said rug-edge, unless a different meaning is clear ircrn the context; and whenever a woven element is characterized as providing a border portion or a border length, there is meant either length of the rug where the rug is elongate; as

already explained. And in the appended claim, the two pairs of such parallel edges are given individual designations, to wit, the two bounding edges of the eld of said main rug component which are parallel with the border portion last referred to are called the primary sides of the eld, while the other two parallel bounding edges of the iield are referred to as the secondary sides thereof.

The word upholstered as used in this specication and in the claim following shall be deemed to be generic and may include or contempate .any one of the following words and expressions, to wit, united; joined; seamed; joined together to form an invisible seam, especially on the right side of the rug. Likewise, the word upholstering as used in the specification and claim shall be deemed to be generic and may include or contemplate any one of the following words and expressions, to Wit, uniting; joining; seaming; joining together to form an invisible seam, especially on the right side of the rug.

Although considerable partcularities of description have been hereinabove set forth, it is emphasized that these are for purposes of illustration and to express present preferences rather than to impose limitations on the scope of protection contemplated, which latter is to be taken from the appended claim, interpreted as broadly as is consistent with the prior art.

I claim:

AA bordered rug made up of a plurality of separate woven rectangular elements upholstered together; said rug including a main element comprising the complete field for therug and at least one complete border for one primary side of said iield, said main element being a section cut from a broadloorn carpet roll woven to include said iield and said border, in combination with an elongate element woven to provide -merely a matching border for one of the secondary sides of said field, and another elongate element woven to provide merely a matching border for the other one of the secondary sides of said eld, said two elongate elements each having two integrally woven rug corners, the opposite end edges of said elements being aligned with the outer edge of the border inst-mentioned, and each of said elongate elements being secured to adjoining rug elementsby a single unidirectional line of upholstering extending uninterruptedly from edge to edge of said rug; all said elements being woven and assembled so that the pile of the completed rug lies substantially uniformly all over the same; said elements being unitarily woven elements; and said elongate elements having camouage mitre-design corners resulting in the illusory visual suggestion that said rug is devoid of any such seam as that last-mentioned.

JAMES H. PATRICK. 

